Flexible Tooling Method and Apparatus

ABSTRACT

A molding apparatus comprises an upper molding box, a lower mold box, an upper flexible membrane covering an opening of the upper mold box, a lower flexible membrane covering an opening of the lower mold box, a heating system located in the upper mold box, a set of ports located between the upper flexible membrane and the lower flexible membrane capable of being used to draw a vacuum between the upper flexible membrane and the lower flexible membrane, and a displacement system located in the lower mold box under the lower flexible membrane.

BACKGROUND INFORMATION

1. Field

The present disclosure relates generally to manufacturing components andin particular to a method and apparatus for manufacturing componentsusing tools. Still more particularly, the present disclosure relates toa method and apparatus for manufacturing components using moldingprocesses with tools.

2. Background

Molding is a process of manufacturing in which a material is shapedusing a tool. This type of tool also may be referred to as a mold. Thesetypes of processes may be used during the manufacturing of aircraft andother vehicles. In particular, molding processes may be used tomanufacture different parts of aircraft interiors. These parts mayinclude, for example, without limitation, ceiling panels, wall panels,doors, side walls, and other suitable parts.

In manufacturing parts, a two part mold may be used. This two part moldmay include a lower side and an upper side. Materials may be placed ontothe lower side of the two part mold. These materials may be laid by handand/or by a computer controlled tool or device. After placement of thematerials on the lower side, the upper side may be placed over the lowerside to encompass the materials laid on the lower side. Thereafter, theupper and lower sides with these materials may be cured in an oven andmay be subjected to vacuum forces during the curing process.

The molds used to manufacture these parts may be dedicated for aspecific part. These types of molds may be cost effective when enoughparts are manufactured over a long enough period of time.

However, design changes may occur to a part. Even a slight design changemay require a change to a mold for the part. Examples of design changes,without limitation, which can occur, include minor or major contourchanges, and/or corrections or revisions to the molded part toaccommodate interface with the addition of a new detail and/orsubassembly. With a change in the design of the part, the mold may needto be modified. In some cases, a new mold may be needed to manufacturethe part.

Modifying a mold may take time and may render the mold useless until themold has been modified. Manufacturing a new mold may be costly and timeconsuming. A new mold may have to be ordered from an outside source. Asa result, manufacturing the part with the design change may not occuruntil receipt of the new mold has occurred. As a result, interruptionsand gaps in the supply of manufactured parts for an aircraft may occur.These gaps and interruptions may lead to increased time needed tomanufacture an aircraft, as well as increasing the costs.

Accordingly, there is a need for a method and apparatus for minimizingthe problems described above. In addition, the logistical issues ofmanaging the utilization and/or availability of numerous molding toolswithin the defined confines of the factory floor may be present. Toolutilization and/or availability may be a major dynamic, which must bemanaged in any successful manufacturing operation.

SUMMARY

In one advantageous embodiment, a molding apparatus comprises an uppermolding box, a lower mold box, an upper flexible membrane covering anopening of the upper mold box, a lower flexible membrane covering anopening of the lower mold box, a heating system located in the uppermold box, a set of ports located between the upper flexible membrane andthe lower flexible membrane capable of being used to draw a vacuumbetween the upper flexible membrane and the lower flexible membrane, anda displacement system located in the lower mold box under the lowerflexible membrane.

In another advantageous embodiment, an apparatus comprises an upper moldbox, a lower mold box, an upper flexible membrane covering an opening ofthe upper mold box, a lower flexible membrane covering an opening of thelower mold box, a heating system located in the upper mold box, a set ofports located between the upper flexible membrane and the lower flexiblemembrane and a displacement system having a vibration unit and a bladderlocated in the lower mold box under the lower flexible membrane. The setof ports may be capable of being used to draw a vacuum between the upperflexible membrane and the lower flexible membrane. The displacementsystem may be capable of displacing a support material to conform to ashape of a part placed between the upper flexible membrane and the lowerflexible membrane to form a conformed surface. The bladder may becapable of being inflated to displace the support material, and thevibrating unit may be capable of placing the support material into apliable state.

In yet another advantageous embodiment, a method is present forprocessing a part. The part may be placed between an upper flexiblemembrane and a lower flexible membrane in a molding apparatus. A vacuummay be applied between the upper flexible membrane and the lowerflexible membrane. A support material located under the lower flexiblemembrane may be placed to conform to a shape of the part to form aconformed surface. The support material may be stiffened after thesupport material has conformed to the shape of the part to form theconformed surface such that the support material and the lower flexiblemembrane substantially maintain the conformed surface.

In a different advantageous embodiment, an apparatus for processingaircraft parts comprises an upper mold box, a lower mold box, an upperflexible membrane covering an opening of the upper mold box, a lowerflexible membrane covering an opening of the lower mold box, a set ofports, and a heating system located in the upper mold box. The set ofports is capable of being used to apply a vacuum between the upperflexible membrane and the lower flexible membrane. The displacementsystem has a vibration unit and a bladder located in the lower mold boxunder the lower flexible membrane. The displacement system is capable ofdisplacing a support material comprising a plurality of spheres toconform to a shape of a part placed between the upper flexible membraneand the lower flexible membrane to form a conformed surface in which thebladder is capable of being inflated to displace the support materialand the vibration unit is capable of placing the support material into apliable state.

In still another advantageous embodiment, a method is present forprocessing aircraft parts. A master part is placed between an upperflexible membrane and a lower flexible membrane in a molding apparatus.A vacuum is applied between the upper flexible membrane and the lowerflexible membrane. A support material located under the lower flexiblemembrane is displaced to conform to a shape of the master part to form aconformed surface by agitating the support material and inflating abladder located under the support material, wherein the supportmaterials comprises a plurality of spheres. Pressure is applied to theupper flexible membrane. The support material is stiffened after thesupport material has conformed to the shape of the master part to formthe conformed surface by applying a second vacuum to the supportmaterial, wherein the second vacuum compacts the support material suchthat the support material and the lower flexible membrane substantiallymaintain the conformed surface, wherein the support material and thelower flexible membrane substantially maintain the conformed surface.The master part is removed after the conformed surface has been formedand the support material has been stiffened. A layer of a heat activatedadhesive is placed on the surface of a preform. The preform is placed onthe conformed surface. A decorative layer is placed over the preform. Avacuum is applied between the preform and the decorative layer, whereinthe decorative layer conforms to a surface of the part. Heat is appliedto the heat activated adhesive. The vacuum applied between the preformand the decorative layer is released after the heat activated adhesivehas attached the decorative layer to the preform

The features, functions, and advantages can be achieved independently invarious embodiments of the present disclosure or may be combined in yetother embodiments in which further details can be seen with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the advantageousembodiments are set forth in the appended claims. The advantageousembodiments, however, as well as a preferred mode of use, furtherobjectives and advantages thereof, will best be understood by referenceto the following detailed description of an advantageous embodiment ofthe present disclosure when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a flow diagram of aircraft production and service methodologyin accordance with an advantageous embodiment;

FIG. 2 is a block diagram of an aircraft in accordance with anadvantageous embodiment;

FIG. 3 is a block diagram of a molding system in accordance with anadvantageous embodiment;

FIG. 4 is a diagram illustrating a perspective view of a moldingapparatus in accordance with an advantageous embodiment;

FIG. 5 is a diagram illustrating a molding apparatus with a part inaccordance with an advantageous embodiment;

FIG. 6 is a diagram illustrating components in a molding apparatus inaccordance with an advantageous embodiment;

FIG. 7 is a diagram illustrating operations to configure a moldingapparatus in accordance with an advantageous embodiment;

FIG. 8 is a diagram illustrating operations to configure a moldingapparatus in accordance with an advantageous embodiment;

FIG. 9 is a diagram illustrating operations to configure a moldingapparatus in accordance with an advantageous embodiment;

FIG. 10 is a diagram illustrating operations to configure a moldingapparatus in accordance with an advantageous embodiment;

FIG. 11 is a diagram illustrating operations to configure a moldingapparatus in accordance with an advantageous embodiment;

FIG. 12 is a diagram illustrating operations to configure a moldingapparatus in accordance with an advantageous embodiment;

FIG. 13 is a diagram illustrating the processing of a part in accordancewith an advantageous embodiment;

FIG. 14 is a diagram illustrating the processing of a part in accordancewith an advantageous embodiment;

FIG. 15 is a diagram illustrating the processing of a part in accordancewith an advantageous embodiment;

FIG. 16 is a diagram illustrating the processing of a part in accordancewith an advantageous embodiment; and

FIG. 17 is a flowchart of a process to configure a molding apparatus inaccordance with an advantageous embodiment;

FIG. 18 is a flowchart of a process for processing a part in accordancewith an advantageous embodiment;

FIG. 19 is a flowchart of a process for deconfiguring a moldingapparatus in accordance with an advantageous embodiment.

DETAILED DESCRIPTION

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 100 as shown in FIG. 1 and an aircraft 102 as shownin FIG. 2. During pre-production, exemplary method 100 may includespecification and design 104 of the aircraft 102 and materialprocurement 106.

During production, component and subassembly manufacturing 108 andsystem integration 110 of the aircraft 102 takes place. Thereafter, theaircraft 102 may go through certification and delivery 112 in order tobe placed in service 114. While in service by a customer, the aircraft102 is scheduled for routine maintenance and service 116 (which may alsoinclude modification, reconfiguration, refurbishment, and so on).

Each of the processes of method 100 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 2, aircraft 102 produced by exemplary method 100 mayinclude an airframe 118 with a plurality of systems 120 and an interior122. Examples of high-level systems 120 include one or more of apropulsion system 124, an electrical system 126, a hydraulic system 128,and an environmental system 130. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of thedisclosure may be applied to other industries, such as the automotiveindustry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 100. Forexample, components or subassemblies corresponding to production process108 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 102 is in service.

Also, one or more apparatus embodiments, method embodiments, or acombination thereof may be utilized during the production stages 108 and110, for example, by substantially expediting assembly of or reducingthe cost of an aircraft 102. Similarly, one or more of apparatusembodiments, method embodiments, or a combination thereof may beutilized while the aircraft 102 is in service, for example and withoutlimitation, to maintenance and service 116.

The different advantageous embodiments recognize that currently usedtools may be expensive to replace or modify. These costs may beespecially high if changes to a part occur frequently or if a part is alimited run part. Additionally, the advantageous embodiments recognizethat the time needed to obtain a new mold or modify a mold may interruptand cause delays in manufacturing parts for an aircraft.

The different advantageous embodiments provide a method and apparatusfor manufacturing parts. A flexible molding apparatus may have an uppermold box, a lower mold box, an upper flexible membrane, a lower flexiblemembrane, a heating system, a set of ports, and a displacement system.The upper flexible membrane may cover an opening of the upper mold boxand the lower flexible membrane may cover an opening of the lower moldbox. This flexible molding apparatus may be configured and reconfiguredquickly to process and/or manufacture parts with different shapes. Thisreconfiguration of the molding apparatus may be performed much morequickly with much less cost as compared to current tooling systems inwhich molds are used.

With reference now to FIG. 3, a block diagram of a molding apparatus isdepicted in accordance with an advantageous embodiment. In this depictedexample, molding apparatus 300 includes upper mold box 302 and lowermold box 304. Upper mold box 302 may include port unit 306, heater unit308, flexible membrane 310, and seal 312. Lower mold box 304 may includeport unit 314, displacement system 316, support material 318, flexiblemembrane 320, seal 322, and port unit 324. As illustrated, displacementsystem 316 may include vibration device 326, bladder 328, and port 330.

In these examples, upper mold box 302 and lower mold box 304 serve as ahousing and/or structure for the different components of moldingapparatus 300. Upper mold box 302 and lower mold box 304 make takevarious shapes and forms. For example, without limitation, these moldboxes may be square, rectangular, hexagonal, trapezoidal, or some othersuitable shape. In the different advantageous embodiments, rectangularand/or square shapes may be a preferred shape for upper mold box 302 andlower mold box 304.

Upper mold box 302 and lower mold box 304 may be made from differentmaterials. For example, without limitation, upper mold box 302 and lowermold box 304 may be made from metal, metal alloys, composite materials,or any other suitable material that may minimize and/or resistdeflection and/or distortion that may occur during a molding process.

Upper mold box 302 may move with respect to lower mold box 304, in theseexamples. Upper mold box 302 may be attached to lower mold box 304 usinghinge unit 332. Hinge unit 332 may be one or more hinges that may besecured to upper mold box 302 and lower mold box 304 in a manner thatallows for upper mold box 302 to move into an open and/or closed state.Upper mold box 302 and lower mold box 304 may be secured to each otherin a closed state using latch system 334.

Flexible membrane 310 may cover upper mold box 302, while flexiblemembrane 320 may cover lower mold box 304. Flexible membrane 310 may beconnected to edges 336 in upper mold box 302. Alternatively, flexiblemembrane 310 may be connected to walls 338 in upper mold box 302. In asimilar fashion, flexible membrane 320 may be connected to edges 340and/or walls 342 of lower mold box 304.

In these examples, flexible membrane 310 and flexible membrane 320 maybe made from any material that provides for flexibility and may be airtight. Additionally, flexible membrane 310 and flexible membrane 320 maybe temperature resistant and thin enough when a vacuum is applied toavoid damaging part 344, which may be placed between these flexiblemembranes. In these examples, part 344 may be, for example, withoutlimitation, a master part, a production part, or some other suitableobject. Flexible membrane 310 and flexible membrane 320 may be made froma material such as, for example, without limitation, a silicone sheet orsome other suitable material. This type of material may be availablefrom Mosites Rubber Company, Inc.

Seal 312 and seal 322 may engage each other when upper mold box 302 isclosed with respect to lower mold box 304. When latch system 334 becomesengaged, seal 312 and seal 322 may form an air tight seal between edges336 and 340.

Port unit 306 in upper mold box 302 may be a set of ports. A set, asused herein, referrers to one or more items. For example, withoutlimitation, a set of ports is one or more ports. Port unit 306 may beused to pressurize space 346 within mold box 302. Heater unit 308 may bea set of heaters capable of generating heat to process part 344.

Port unit 314 in lower mold box 304 may be used to apply a vacuum tospace 348 within lower mold box 304. Displacement system 316 maydisplace support material 318. Displacement system 316 may displacesupport material 318 in a number of different ways. For example, withoutlimitation, vibration device 326 may agitate support material 318.Agitation of support material 318 may cause support material 318 toenter a pliable state, allowing support material 318 to conform and/orchange shape. This pliable state may be, for example, withoutlimitation, a fluid state.

Bladder 328 may be increased in size through port 330 to furtherdisplace support material 318. In particular, bladder 328 may increasein size to lift support material 318 upwards against flexible membrane320. Port unit 324 may be a set of ports integrated within seal 322 todraw a vacuum in space 350 between flexible membrane 310 and flexiblemembrane 320.

Support material 318 may take various forms. For example, withoutlimitation, support material 318 may take the form of pellets, spheres,or some other element that may be reconfigured in shape. In theseexamples, support material 318 may take the form of Macrolite® ceramicspheres, which may be obtained from Kinetico Corporation. These spheresmay range in a size from around 0.020 inches to around 0.25 inches indiameter. Of course, any suitable type and/or size of support media thatmay be reconfigured in shape and hold a reconfigure shape may be used.

In operation, part 344 may be a master tool or part used to reconfiguremolding apparatus 300. In other advantageous embodiments, part 344 maybe an actual production part for processing by molding apparatus 300.

Part 344 may be placed between flexible membrane 310 and flexiblemembrane 320. Upper mold box 302 may be closed with respect to lowermold box 304. Latch system 334 may be engaged to form a seal betweenseal 312 and seal 322. A vacuum may be applied through port 324 to space350. This vacuum may cause flexible membrane 310 and flexible membrane320 to conform to a shape of part 344. In addition, pressure may beapplied in space 346 through port unit 306 to aid in conforming flexiblemembrane 310 to surface 352 of part 344, and flexible membrane 320 mayconform to surface 354 of part 344.

Vibration device 326 may be activated to displace support material 318.This displacement may cause support material 318 to become pliable suchthat support material 318 may change shape. Bladder 328 may be filledwith a gas through port 330 to lift support material 318 upwards intocontact with flexible membrane 320. In this manner, support material 318also may conform to the shape of surface 354 of part 344.

Once flexible membrane 320 and support material 318 have been configuredto a shape of surface 354, a vacuum may be applied to space 348 usingport unit 314. This vacuum may change the state of support material 318to a rigid and/or solid state from the pliable state. Vibration device326 may reduce and/or cease agitation of support material 318 inaddition to a vacuum being applied to space 348. In this state, supportmaterial 318 and flexible membrane 320 may retain the shape of surface354 for part 344. At this point, pressure in space 346 may be reducedand/or released and latch system 334 may be disengaged to allow forremoval of part 344. Further, the vacuum applied to space 350 may bereleased.

Another part, such as part 356, for example, without limitation, may bethe same shape as part 344 and may be placed onto flexible membrane 320.Part 344 may be, for example, without limitation, a preform or someother part for processing. A perform may be a material that has nopreliminary shaping, but is not yet in a final form or completed. Inthis configuration, surface 358 of part 356 may easily be held byflexible membrane 320 and support material 318. Additionally, part 356may include adhesive 360 on surface 362. Adhesive 360 may be applied tosurface 362 prior to part 356 being placed onto flexible membrane 320.In other advantageous embodiments, adhesive 360 may be placed ontosurface 362 after part 356 has been placed onto flexible membrane 320.In this example, layer 364 may be laid across seal 322.

Upper mold box 302 may be closed, and latch system 334 may be engaged. Avacuum may be applied to space 350. This vacuum may occur between layer364 and flexible membrane 320 in this example. Additionally, pressurealso may be applied to space 346 to cause flexible membrane 310 toconform to surface 362 of part 356.

As a result, layer 364 may be pushed or placed against adhesive 360 onpart 356. Heat may be generated by heater unit 308 to activate adhesive360. In these examples, adhesive 360 may be a heat activated adhesive.Of course, other types of adhesives may be used, such as, for example,without limitation, pressure sensitive or contact adhesives, dependingon the particular implementation.

Heater unit 308 may continue to apply heat until adhesive 360 secureslayer 364 to surface 362. Afterwards, heat may be discontinued and thepressure applied to space 346 and the vacuum applied to space 350 may bediscontinued. At this point, latch system 334 may be disengaged andupper mold box 302 may be opened to remove part 356. At this point,another similar part may be processed in a similar fashion. Whileprocessing parts having the same shape as part 344 with moldingapparatus 300, the vacuum may be maintained in space 348 and bladder 328may remain filled (regulated) to maintain support material 318 andflexible membrane 320 in the configured shape.

If a part with a different shape is to be processed, the vacuum appliedto space 348 may be removed and bladder 328 may be deflated to readymolding apparatus 300 for reconfiguration to another shape for anotherpart.

With reference now to FIG. 4, a diagram illustrating a perspective viewof a molding apparatus is depicted in accordance with an advantageousembodiment. Molding apparatus 400 may be an example of one advantageousembodiment of molding apparatus 300 in FIG. 3.

As illustrated, molding apparatus 400 includes upper mold box 402 andlower mold box 404. As can be seen, from this illustration, upper moldbox 402 includes walls 406, which includes walls that extend downwardfrom top 408. Walls 406, in these examples, may be four walls in whicheach pair of walls oppose each other. Lower mold box 404 also may haveopposing walls 410, which may extend upward from base 412. In thisillustrative example, wheels 414, 416, and 418 may be attached to base412, and may provide mobility and/or portability for molding apparatus400. An additional wheel, not shown in this view, also may be connectedto base 412.

In these examples, vibration units 420, 422, 424, 426, and 428 may bepresent within wall 430, extend through space 348 in FIG. 3 of lowermold box 404 in FIG. 4, and may be similarly present in the opposingwall of lower mold box 404. Additionally, these vibration units also mayprovide a connection to displace the support media within lower mold box404. Additionally, latches 432, 434, 436, 438, 440, and 442 may bepresent on wall 424 of walls 410. These latches may be part of latchsystem 334, such as latch system 334 in FIG. 3, and may be used tosecure upper mold box 402 to lower mold box 404.

Turning now to FIG. 5, a diagram illustrating a molding apparatus with apart is depicted in accordance with an advantageous embodiment. In thisexample, molding apparatus 400 is shown in an open state in which uppermold box 402 is shown in a raised position with respect to lower moldbox 404.

In this view of molding apparatus 400, flexible membrane 500 is showncovering lower portion 502 of upper mold box 402. Flexible membrane 504is shown as covering upper portion 506 of lower mold box 404.

In this illustrative example, part 508 may be a mold master. Part 508may be placed on flexible membrane 504. With part 508 in place onflexible membrane 504, upper mold box 402 may be moved into a closedposition to create an imprint of contoured surfaces 510 on part 508.Contoured surfaces 510 may be both on upper surface 512 and lowersurface 514 of part 508. Contoured surfaces 510 may be configured and/orimprinted in both flexible membrane 500 and flexible membrane 504, inthese examples.

Molding apparatus 400 may create an imprint of a particular shape oflower surface 514 for part 508 on flexible membrane 504. In other words,molding apparatus 400 may be configured as a mold to process parts thatmay have a shape similar to part 508. Further, molding apparatus 400also may be quickly reconfigured to adapt and form a surface to acontour for a different shape. In this manner, the reconfiguration ofmolding apparatus 400 may provide a complex, contoured surface for avariety of shapes using molding apparatus 400. This type ofconfiguration and/or reconfiguration of molding apparatus 400 may occurin a short period of time with little cost, as compared to currentlyused molding systems.

With reference now to FIGS. 6-11, diagrams illustrating operations toconfigure a molding apparatus are depicted in accordance with anadvantageous embodiment. In FIG. 6, a diagram illustrating across-sectional view of a molding apparatus is depicted in accordancewith an advantageous embodiment.

In this example, molding apparatus 600 is an example of anotheradvantageous embodiment of molding apparatus 300 in FIG. 3. In thisexample, molding apparatus 600 may have upper mold box 602 and lowermold box 604. Upper mold box 602 may include heaters 606, 608, 610, and612, which may be mounted on inner surface 614 of top 616. Additionally,upper flexible membrane 618 covers opening 620 of upper mold box 602.Additionally, seal 622 may be located over a portion of upper flexiblemembrane 618. Upper mold box 602 also may include port 609 and port 611.These ports may be used to pressurize space 613 within upper mold box602.

Lower mold box 604 may include lower flexible membrane 624, which coversopening 626 of lower mold box 604. Lower mold box 604 also may includevacuum pipes 628 and 630. In this particular example, vacuum pipes 628and 630 may pass through seal 623. These vacuum pipes may apply a vacuumin any space that may be between upper flexible membrane 618 and lowerflexible membrane 624 when upper mold box 602 is in a closed positionwith respect to lower mold box 604. Additionally, seal 623 may belocated over a portion of lower flexible membrane 624. Seal 623 may bepositioned relative to seal 622, such that an air tight seal may bepresent when upper mold box 602 is placed into a closed position withrespect to lower mold box 604.

Lower mold box 604 may include port 632 and bladder 634. Port 632 may beused to introduce and remove air from bladder 634. Additionally, vacuumpipe 636 and vacuum pipe 637 also may be present within lower mold box604 to apply a vacuum in space 638.

In this example, support material 640 may be placed in space 638 withinlower mold box 604 under lower flexible membrane 624. Vibration unit 642also may be present within space 638. Vibration unit 642 may operate tocause support material 640 to change form or shape. In particular,vibration unit 642 may cause support material 640 to take a pliablestate.

Support material 640 may be considered to be in a pliable state whensupport material 640 becomes capable of continually deforming orflowing. This flowing or deformation may occur under applied shearstress regardless of the amount of applied stress. In these examples,vibration unit 642 and bladder 634 may form a displacement system, suchas, for example, without limitation, displacement system 316 in FIG. 3.

In this example, master part 644 may be placed in space 646 betweenlower flexible membrane 624 and upper flexible membrane 618. Master part644 is an example of one implementation of part 344 in FIG. 3. In thisexample, master part 644 may be a master mold shape for a part to beprocessed. In other advantageous embodiments, master part 644 may be anactual production part.

In FIG. 7, upper mold box 602 may be moved into a closed position withrespect to lower mold box 604. Vacuum 700 may be applied in space 646,which may be between upper flexible membrane 618 and lower flexiblemembrane 624 where master part 644 is located. As can be seen, in thisexample, upper flexible membrane 618 and lower flexible membrane 624 mayconform to the shape of master part 644. In particular, upper flexiblemembrane 618 may conform to surface 704 of master part 644, while lowerflexible membrane 624 may conform to surface 706 of master part 644.

In FIG. 8, inflation pressure 800 may be applied within upper mold box602 by introducing air and/or some other suitable gas into space 613through ports 609 and 611. Inflation pressure 800 may cause upperflexible membrane 618 to contact surface 704 and/or more securelycontact surface 704 of master part 644. Support material 640 may beagitated using vibration unit 642 to enter a pliable state. Pressure 802may be applied to bladder 634 through port 632. This application ofpressure may increase the size of bladder 634. As a result, supportmaterial 640 may move to conform to lower flexible membrane 624, whichmay have the shape of master part 644. A reduced vacuum is concurrentlyapplied to space 638 through vacuum pipe 636 and vacuum pipe 637 tofurther enhance the motion of support material 640 to conform to lowerflexible membrane 624.

In FIG. 9, pressure 802 may continue, now in a regulated manner, to beapplied to bladder 634 through port 632 to raise the level of supportmaterial 640 to cause further contact and conformance in a shape withinlower flexible membrane 624. At this point, the agitation of supportmaterial 640 may be reduced to reduce the pliability of support material640. In this step, full vacuum 900 may be applied through vacuum pipe628 and vacuum pipe 630.

In FIG. 10, vacuum 700, applied through vacuum pipes 628 and 630, may bereleased such that a vacuum may no longer be present in space 646between upper flexible membrane 618 and lower flexible membrane 624.Further, inflation pressure 800, applied through ports 609 and 611, alsomay be released. At this point, upper mold box 602 may be opened.

In FIG. 11, master part 644 may be removed. At this point, moldingapparatus 600 may be configured and ready to process parts having ashape similar to master part 644.

With reference now to FIGS. 12-16, diagrams illustrating the processingof a part are depicted in accordance with an advantageous embodiment. Inthis example, preform 1200 is an example of one implementation for part356 in FIG. 3. Preform 1200 is an example of a part that may beprocessed using a decorative lamination process with molding apparatus600 in its configured condition.

In FIG. 12, preform 1200 may be placed onto lower flexible membrane 624within molding apparatus 600 in the configured condition. Preform 1200may easily fit onto lower flexible membrane 624 in the configuredcondition.

Additionally, adhesive 1202 may be placed on surface 1204 of preform1200. Adhesive 1202 may be place on surface 1204 prior to and/or afterpreform 1200 has been placed onto lower flexible membrane 624. In thisoperation, decorative layer 1206 may be placed across seal 623 of lowermold box 604. Space 1208 may be present between decorative layer 1206and preform 1200.

In this example, adhesive 1202 may be, for example, without limitation,a heat activated adhesive. Of course, other types of adhesives may beused. For example, without limitation, a pressure sensitive adhesive, aultra-violet light adhesive, a light activated adhesive, or some othersuitable adhesive may be used. With the use of other adhesives, anactivation mechanism other than heaters 606, 608, 610, and 612 may beused. For example, without limitation, with the use of a ultra-violetlight activated adhesive, ultra-violet lights may be used in place ofthe heaters.

In FIG. 13, upper mold box 602 may be closed such that seal 622 contactsseal 623. Upper mold box 602 may be secured to lower mold box 604, inthis example, to create an airtight seal. Heat 1300 may be generatedusing heaters 606, 608, 610, and 612. As can be seen, in these examples,heat 1300 penetrates through upper flexible membrane 618 into adhesive1202 and/or preform 1200. Heat 1300 may activate adhesive 1202 in thisexample.

In FIG. 14, vacuum 1400 may be applied through vacuum pipes 628 and 630in a manner that may cause decorative layer 1206 to adhere to and/orcontact adhesive 1202 and/or preform 1200.

In FIG. 15, the generation of heat 1300 may cease. Additionally, vacuum1400, applied through vacuum pipes 628 and 630, may be removed. Uppermold box 602 may be raised with respect to lower mold box 604. Preform1200, with decorative layer 1206 attached to preform 1200, throughadhesive 1202, may be removed.

In FIG. 16, vacuum 900 and pressure 802 may be released. At this point,molding apparatus 600 may be reconfigured for a different shape and/orpart. If the same shape is used, then vacuum 900 and pressure 802 may bemaintained.

With reference now to FIG. 17, a flowchart of a process to configure amolding apparatus is depicted in accordance with an advantageousembodiment. The process illustrated in FIG. 17 may be used to configurea molding apparatus, such as molding apparatus 300 in FIG. 3 for use inmanufacturing and/or processing a part.

The process begins with placement of a contoured part in the moldingapparatus between the upper flexible membrane and the lower flexiblemembrane (operation 1700). The contoured part may be, for example,without limitation, master part 644 as shown in FIG. 6. The upper moldbox may be closed over the lower mold box (operation 1702). The uppermold box may be secured to the lower mold box (operation 1704). Theupper mold box may be secured to the lower mold box using varioussecuring mechanisms such as, for example, without limitation, latches orother securing mechanisms.

A vacuum may be applied between the upper flexible membrane and thelower flexible membrane (operation 1706). This vacuum may cause theupper flexible membrane and the lower flexible membrane to conformand/or take the shape of the contoured part. Inflation pressure may beapplied to the upper mold box (operation 1708).

The process also may displace the support material in the lower mold box(operation 1710). In operation 1710, the support material may bedisplaced in these examples through agitation using a vibration unit. Inthis particular example, the support material may take the form ofMacrolite® spheres and/or beads. The process also may apply inflationpressure to a bladder in the lower mold box (operation 1712). Byincreasing the size of the bladder in the lower mold box, the bladdermay inflate to raise the support material towards and/or against thelower flexible membrane. This bladder also may be considered part of thedisplacement apparatus for the support material.

The process may slow down the pliability of the support material(operation 1714). In this operation, the agitation of the supportmaterial may be reduced to decrease the pliability or moveability of thesupport material. The process also may apply a vacuum on the supportmaterial (operation 1716). Operation 1716 may rigidize and/or solidifythe support material units contoured shape against a flexible membrane.In this manner, the contoured shape of the flexible membrane in thelower mold box and the support material will retain the shape of thecontoured part.

The process may release the vacuum applied between the upper flexiblemembrane and the lower flexible membrane (operation 1718). The processalso may release pressure on the upper mold box (operation 1720). Thesecuring mechanism holding the upper mold box in place with respect tothe lower mold box may be disengaged (operation 1722), and the uppermold box may be opened with respect to the lower mold box (operation1724). The contoured part may be removed (operation 1726) with theprocess terminating thereafter. At this time, the molding apparatusconfigured for use in processing part having a shape similar to thecontoured part.

With reference now to FIG. 18, a flowchart of a process for processing apart is depicted in accordance with an advantageous embodiment. Theprocess illustrated in FIG. 18 may be performed using a moldingapparatus such as molding apparatus 300 in FIG. 3 in a configured state.

The process begins with placement of a contoured part onto the lowerflexible membrane having the contoured shape to receive the contouredpart (operation 1800). The contoured part may be preform 1200 in FIG. 12and may have an activated adhesive, such as adhesive 1202 in FIG. 12,which may have been previously applied before placement of the contouredpart onto the lower flexible membrane. In other advantageousembodiments, this adhesive may be applied after the contoured part hasbeen placed into the molding apparatus.

The process then may place a layer across the seal along the peripheraledge of the lower mold box (operation 1802). This seal may be, forexample, without limitation, seal 623 in FIG. 6. In these examples, thislayer may be, for example, without limitation, decorative layer 1206 inFIG. 12. This layer may be implemented using, for example, withoutlimitation, a Tedlar® decorative film or layer. Tedlar® films may beavailable from E. I. du pont de Nemours and company. Tedlar® is aregistered trademark of E. I. du pont de Nemours and company.Thereafter, the upper mold box may be closed with respect to the lowermold box (operation 1804). The process then may secure the upper moldbox to the lower mold box using a securing mechanism (operation 1806).Latch system 334 in FIG. 3 is one non-limiting example of a securingmechanism that may be used.

Next, heat may be applied from a heat source within the upper mold box(operation 1808). Additionally, a vacuum may be applied in the areabetween the layer and the lower flexible membrane (operation 1810). Thisvacuum may be applied between the layer and the flexible membrane tocause the layer to conform to the shape of the contoured part. The heatin operation 1808 may activate the heat activated adhesive in a mannerthat bonds the layer to the contoured part. Application of heat may beceased after a selected period of time (operation 1812). The vacuum maythen released (operation 1814). Next, the securing mechanism may bedisengaged (operation 1816), and the upper mold box may be opened withrespect to the lower mold box (operation 1818). The process contouredpart may then be removed (operation 1820) with the process terminatingthereafter.

With reference now to FIG. 19, a process for deconfiguring a moldingapparatus is depicted in accordance with an advantageous embodiment. Ifthe current configuration for the molding apparatus is no longer needed,this process may be implemented to allow a new configuration to be madein molding apparatus 300 in FIG. 3.

The process begins by releasing the vacuum on the support material onthe lower mold box (operation 1900). The process may release thepressure on the bladder in the lower mold box (operation 1902). Byreleasing the vacuum and the pressure, the support material may then beready to be redisplaced and/or formed for the next part.

The different operations illustrated in the flowcharts may illustratethe architecture, functionality, and operation of some possibleimplementations of methods and apparatus for processing part. In somealternative implementations, the operation or operations noted in theblocks may occur out of order. For example, in some cases, twooperations show in succession may be executed substantiallyconcurrently. In other advantageous embodiments, two operationsillustrated in the blocks may be executed in reverse order, depending onthe functionality involved.

Thus, the different advantageous embodiments provide a method andapparatus for processing parts. In the different advantageousembodiments, a molding apparatus and a method may be provided toconfigure a tool to process a part. The molding apparatus, in theillustrative examples, may be configured to process a part having aparticular shape without requiring a new tool or modifications that mayrequire time and expense as compared to currently used molding systems.

Further, in the different advantageous embodiments, a single moldingapparatus may be reconfigured after a set number of uses much morequickly than currently available molding systems. Thus, the differentadvantageous embodiments may reduce interruptions in the processing ormanufacturing of a part. Further, the different advantageous embodimentsalso may provide for a reduced cost in manufacturing parts because newmolds may not be required each time new shape is present for a part.

The description of the different advantageous embodiments has beenpresented for purposes of illustration and description, and is notintended to be exhaustive or limited to the embodiments in the formdisclosed. Many modifications and variations will be apparent to thoseof ordinary skill in the art. In these different advantageousembodiments, a decorative layer may be placed and secured to a part inprocessing a part using a mold. In other advantageous embodiments, othercomponents may be processed. Other parts that may be processed include,for example, without limitation, protective films, art work, hard rigidfixtures, hooks, latches, window reveals, and other suitable componentsmay be attached to a part. Further, different advantageous embodimentsmay provide different advantages as compared to other advantageousembodiments. The embodiment or embodiments selected are chosen anddescribed in order to best explain the principles of the embodiments,the practical application, and to enable others of ordinary skill in theart to understand the disclosure for various embodiments with variousmodifications as are suited to the particular use contemplated.

1. A molding apparatus comprising: an upper mold box; a lower mold box;an upper flexible membrane covering an opening of the upper mold box; alower flexible membrane covering an opening of the lower mold box; anumber of heaters configured to generate heat; a set of ports capable ofbeing used to apply a vacuum between the upper flexible membrane and thelower flexible membrane; and a displacement system located in the lowermold box under the lower flexible membrane.
 2. The molding apparatus ofclaim 1, wherein the displacement system is capable of displacing asupport material to conform to a shape of a part placed between theupper flexible membrane and the lower flexible membrane to form aconformed surface.
 3. The molding apparatus of claim 1, wherein thedisplacement system comprises: a vibration unit located in the lowermold box under the lower flexible membrane.
 4. The molding apparatus ofclaim 3, wherein the vibration unit is capable of placing the supportmaterial into a pliable state.
 5. The molding apparatus of claim 1,wherein the displacement system further comprises: a bladder located inthe lower mold box under the lower flexible membrane.
 6. The moldingapparatus of claim 5, wherein the bladder is capable of being inflatedto displace the support material.
 7. The molding apparatus of claim 2,wherein the support material comprises a plurality of spheres.
 8. Themolding apparatus of claim 1, wherein the set of ports is located on thelower mold box.
 9. An apparatus comprising: an upper mold box; a lowermold box; an upper flexible membrane covering an opening of the uppermold box; a lower flexible membrane covering an opening of the lowermold box; a set of ports capable of being used to apply a vacuum betweenthe upper flexible membrane and the lower flexible membrane; and adisplacement system having a vibration unit and a bladder located in thelower mold box under the lower flexible membrane, wherein thedisplacement system is capable of displacing a support material toconform to a shape of a part placed between the upper flexible membraneand the lower flexible membrane to form a conformed surface in which thebladder is capable of being inflated to displace the support materialand the vibration unit is capable of placing the support material into apliable state.
 10. The apparatus of claim 9 further comprising: aheating system located in the upper mold box. 11.-20. (canceled)
 21. Anapparatus for processing aircraft parts comprising: an upper mold box; alower mold box; an upper flexible membrane covering an opening of theupper mold box; a lower flexible membrane covering an opening of thelower mold box; a set of ports capable of being used to apply a vacuumbetween the upper flexible membrane and the lower flexible membrane; aheating system located in the upper mold box; and a displacement systemhaving a vibration unit and a bladder located in the lower mold boxunder the lower flexible membrane, wherein the displacement system iscapable of displacing a support material comprising a plurality ofspheres to conform to a shape of a part placed between the upperflexible membrane and the lower flexible membrane to form a conformedsurface in which the bladder is capable of being inflated to displacethe support material and the vibration unit is capable of placing thesupport material into a pliable state.
 22. (canceled)